Step 4: Sanding and Glue Up

Step 5: Paint!

Finally to the fun part! I found the following image on the web. I'm sure it is somehow a trademark of Lego Group but this is what I copied for the pa...

Last year I saw a great "ible" about making an adult lego costume. I loved the idea of the big minifig head so I proposed this to my six year old. He immediately agreed but upped the ante. "How about Lego Indiana Jones?!?" How can a father say no to that kind of enthusiasm? This is my first instructable, but I have been lurking for a couple years so let me know what you think, or how I can improve future posts. It is specific to Lego Indiana Jones, but could obviously be applied to any lego figure you are interested in making. (Lego Freddy Mercury?)

Foam is 2' x 8' insulation board which can be found at HomeDepot, Lowe's or your local building supply store. It usually comes in Pink, Purple, or Blue. I just cut it into squares. It can be cut with a long box knife pretty easily.

I absolutely love this design, look everything! Your Amazing! So, for my 5 yr son we gave it a try! but changed the character to a Lego city Police officer. Thank you so much for sharing..You made my son Halloween costume possible!

I made a similar one for my son. The front is the screen so he could see and breath. I was a little hard for him to see but another boy helped him on the steps. It was fun, and we're already looking at something bigger for next year.

It went great! He didn't have any overheating problems, but the head was a bit bulky, so after a while we carried it for him from door to door. The greatest thing was that everyone knew who he was, so it was a success! Thanks for sharing this awesome idea!

I have to say, my son was crazy impressed with this costume. He is slowly working his way through video game right now. Perhaps some black netting for the eyes and making vent holes out of the stubble to improve ventilation? Otherwise, this is perfect!

Seeing this, I'm sure you could actually mod this so that there are different "stickers" you can apply and take off to change the face and body for anyone who wants to be able to reuse this and be a different LEGO character each Halloween.

Awesome! Getting your son's buy-in was critical; the fact that he ended up bailing due to being boiled alive is no reflection on the awesomeness of the concept -- you just have to do it better next year (this year?) :-)